Substantially non-porous polyurethane plastic and method for producing same



United States Patent 14 Claims. (Cl. 250-18) The present invention relates to a new series of resins, compositions of matter containing same and to the method of preparing such products. This application is a continuation of my application Serial No. 373,036 filed August 7, 1953, now Patent No. 3,102,875, issued September 3, 1963.

The products of this invention are suitable for casting or pouring into intricate forms or crevices and are adapted for use in numerous applications, for example, as adhesives, protective coatings, components of insulating varnishes, impregnants for fibrous material to impart Water resistance, flame resistance and improved hand thereto; as insulating and dielectric elements in transformers, capacitors, electrical terminals or bushings, cables or other electric devices; and as foamed-in-place resins. The products of relatively low molecular weight, that is, those derived from monoamines, monohydroxy compounds or monomercaptans, find use as plasticizers for vinyl resins and numerous other plastic materials.

In accordance with the instant invention, the new products are prepared by reacting an organic compound containing at least one urethane or thiourethane group with a compound of the general formula: R(NCX) wherein R is an organic radical free from functional groups other than -NCX, urethane and thiourethane groups, X is selected from the group consisting of oxygen and sulfur, and n is an integer having a value of at least 2, the second-mentioned reactant being employed in an amount suflicient to react with the urethane and/ or thiourethane groups of the first-mentioned reactant. More specifically, the new products are prepared by reacting an organic compound containing a plurality of urethane and/ or thiourethane groups with a compound of the above general formula wherein n is an integer having a value of at least 2, the second-mentioned reactant being employed in an amount sufiicient to react with at least two urethane groups or one urethane and one thiourethane group of the first-mentioned reactant.

The organic compounds containing at least one urethane or thiourethane group and preferably a plurality of these groups may be prepared in any suitable manner. For example, compounds containing urethane groups are prepared by reacting an organic hydroxy compound, preferably an organic polyhydroxy compound, with polyisocyanates, carbamyl halides such as carbamyl chloride, urea or substituted ureas; or by reacting monoor polyamines with halocarbonates such as chlorocarbonates. Compounds containing thiourethane groups are prepared by reacting polyisocyanates With mercaptans or polymercapto compounds.

As illustrative examples of suitable hydroxy compounds for use in the production of organic compounds containing urethane groups, there may be mentioned methyl alcohol, ethyl alcohol, propyl alcohol, isopropyl alcohol, butyl alcohol, amyl alcohol, hexyl alcohol, octyl alcohol, decyl alcohol, lauryl alcohol, allyl alcohol, oleyl alcohol, tridecyl alcohol, stearyl alcohol, methyl ricinoleate, ethyl lactate, diglycerides, monoesters of glycols,

3,143,517 Patented Aug. 4, 1954 ice phenols, substituted phenols, alkylene oxide condensates of these hydroxy compounds, ethylene glycol, propylene glycol, butylene glycol-2,3 butylene glycol-1,3, Z-methyl pentanediol-2,4, 2-ethylhexane-diol- 1,3, hexamethylene glycol, styrene glycol, N-phenyl diethanolarnine, catechol, resorciriol, 2,2-bis(4-hydroxyphenyl)propane, p,p-dihydroxybiphenyl, decamethylene glycol; polyglycols (ether glycols) such as polyethylene glycols, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycols 200, 400 and 600; polypropylene glycols, dipropylene glycol, tripropylene glycol, polypropylene glycols 400, 750, 1200 and 2000; Carbowaxes 1000, 1000 W, 1500; monoethers of trihydroxy compounds such as glycerylalpha-allyl ether, glyceryl-alpha-phenyl ether, glycerylalpha-isopropyl ether; hydroxy esters such as an ester prepared from 1 mol of dibasic acid and 2 mols of a glycol or polyglycol, a polyester prepared so that the molar ratio of glycol or polyglycol to the dibasic acid is between 2 and 1, an ester prepared from 1 mol of a dimer acid and 2 mols of a glycol or polyglycol, an ester prepared from a hydroxy acid and a glycol or polyglycol so that the molar ratio of the glycol or polyglycol to the hydroxy acid is between 0.5 and 1 and an ester prepared from 1 mol of a trihydroxy compound and 1 mol of a monobasic acid, such as the monoglyceride of eleostearic acid; trihydroxy compounds such as glycerine, triethanolamine, pyrogallol, phloroglucinol, etc., alkylene oxide condensates of glycerine, triethanolamine, pyrogallol, phloroglucinol, etc.; monoethers of tetrahydroxy compounds; esters prepared from hydroxy acid and a trihydroxy compound so that the molar ratio of the latter to the former is between 0.33 and 1, such as glycerine triricinoleate, esters prepared from 1 mol of a monobasic acid and 1 mol of a tetrahydroxy compound; tetrahydroxy compounds such as pentaerythritol, etc., alkylene oxide condensates of pentaerythritol, etc., esters prepared from 1 mol of a dibasic acid and 2 mols of a trihydroxy compound; pentahydroxy compounds, such as arabitol, xylitol, etc., hexahydroxy compounds such as sorbitol, ducitol and mannitol, etc.

Examples of suitable compounds which may be reacted with polyisocyanat'es to form thiourethanes are methyl mercaptan, ethyl mercaptan, butyl mercaptan, octyl mercaptan, cyclohexyl mercaptan, octadecyl mercaptan, allyl mercaptan, phenyl mercaptan, tolyl mercaptan, alphanaphthyl mercaptan, dimercaptoethane, 1,2,3-trimercaptopropane, 1,2,3-trimercaptobutane, 1,5-dimercapto- 3-(mercaptomethyl)pentane, 1,6-dimercaptohexane, 1,10- dimercaptodecane, 1,6-dirnercapto-3-methylhexane, 1,4- dimercaptobenzene, dimercaptoxylylene, and polyvinyl mercaptan.

Illustrative examples of suitable isocyanates, isothiocyanates, carbamyl chlorides, and ureas which may be employed in the production of organic compounds containing urethane or thiourethane groups are ethyl, methyl, propyl, butyl, amyl, octyl, decyl, dodecyl, hexadecyl, octadecyl, allyl, isobutyl, isoamyl, cyclohexyl, phenyl, ptolyl, p-chlorophenyl, m-chlorophenyl and alpha-naphthyl isocyanates, etc.; ethylene diisocyanate, tn'methylene diisocyanate, tetramethylene diisocyanate, pentamethylene diisocyanate, etc.; and the corresponding diisothiocyanates; alkylene diisocyanates and diisothiocyanates, such as propylene-1,Z-diisocyanate, butylene-l,2-diis0- cyanate, butylene-1,3-diisocyanate, butylene 2,3 diisocyanate, and butylene-1,3-diisothiocyanate; alkylidene diisocyanates and diisothiocyanates, such as ethylidine diisocyanate, butylidine diisocyanate and ethylidine diisothiocyanate; cycloalkylene diisocyanates and diisothiocyanates, such as cyclopentylene-1,3-diisocyanate, cyclohexylene-1,2-diisocyanate, cyclohexylene 1,3 diisocyanate, cyclohexylene-1,4-diisocyanate, and cyclohexylene- 1,2-diisothiocyanate; cycloalkylidene diisocyanates and 3 diisothiocyanates, such as cyclopentylidene diisocyanate, cyclohexylidene diisocyanate and cyclohexylidene diisothiocyanate; aromatic diisocyanates and diisothiocyanates, such as m-phenylene diisocyanate, p-phenylene diisocyanate, 1-methyl-2,4-phenylene diisocyanate, naphthylene-1,4-diisocyanate, diphenylene-4,4-diisocyanate or p-phenylene diisothiocyanate; aliphatic-aromatic diisocyanates or diisothiocyanates, such as xylylene-1,4-diisocyanate, xylylene-l,3-diisocyanate, 4,4-diphenylmethane diisocyanate, 4,4'-diphenylpropane diisocyanate or xylylene-1,4-diisothiocyanate; methyl, ethyl, propyl, butyl, octyl, dodecyl, octadecyl, phenyl cyclohexyl, p-chlorophenyl carbamyl chlorides; m-phenylene, p-phenylene, 2,4-tolylene, 4,4-xenylene bis-carbamyl chlorides; urea, methylurea, ethylurea, butylurea, phenylurea, alphanaphthylurea, cyclohexylurea, s-dimethylurea, s-dicyclohexylurea, s-diphenylurea, 1,3-methylethylurea and 1,3- ethylphenylurea, etc. 7

Examples of amines which may be used in the preparation of organic compounds containing urethane groups are: methyl, ethyl, butyl, octyl, cyclohexyl, octadecyl, allyl amines, aniline, p-toluidine, substituted anilines and alpha-naphthylamine; ethylene diamine, trimethylene diamine, tetramethylene diamine, hexamethylene diamine, octamethylene diarnine, decamethylene diamine, dodecamethylene diamine, N,N'-dirnethyl decamethylene diamine, N,N'-dibenzyl hexamethylene diamine, cyclohexylene 1,4 diamine, ortho phenylene diamine, m-phenyl ene diamine, p-phenylene diamine, benzidine, naphthalene- 1,4-diamine,'gamma,gamma'-diamino dibutyl oxide, gamma,gamrna'-diamino dibutyl sulfide, diethylene triamine and triethylene tetramine, etc.

As typical examples of halocarbonates which may be reacted with amines to form organic compounds containing urethane groups, there may be mentioned methyl, ethyl, propyl, isopropyl, butyl, cyclohexyl, phenyl, p-tolyl and p-chlorophenyl chlorocanbonates and butylene-1,4- and hexylene-1,6-bis-chlorocarbonates, etc.

The organic compounds containing urethane and/or thiourethane groups used in the practice of the instant invention are preferably prepared by reacting an organic compound of the general formula: R(NCX) with an organic polyhydroxy and/ or polymercapto compound in the proportions providing a ratio of NCX groups to active hydrogen atoms which is greater than 1:1 but is desirably within the range of 1.1:1 to n: 1. More specificcally, these reactants are employed in the proportions providing a ratio of NCX groups to active hydrogen atoms which falls in the range of about 1.3:1 or 1.5:1 to about 12:1 and preferably within the range of about 2:1 to about ml. The products obtained by this reaction are adducts which contain urethane and/or thiourethane groups and also free isocyanate and/or isothiocyanate groups. Therefore, these products can be converted into more highly polymerized products by bringing out a reaction between the isocyanate and/or isothiocyanate groups, of one molecule with the urethane and/or thiourethane groups of the same or another molecule. This is achieved by heating the adducts in the substantial absence of moisture or by means of catalysts. Alternatively, the organic compounds containing urethane and/or thiourethane groups and also isocyanate and/ or isothiocyanate groups may be converted into a more highly polymerized state by further reaction with a polyisocyanate and/or polyisothiocyanate.

The products of the instant invention may be in the form of bubble-free resinous compositions or highly cellular resinous foams, the character of the products being dependent upon the conditions of manufacture.

For example, if a substantially bubble-free resin is desired, the reaction between the organic compound containing urethane and/ or thiourethane groups with a polyisocyanate and/or polyisothiocyanate is desirably carried out in the absence of a catalyst and also moisture. On the other hand, if a cellularproduct is desired, the reac- 7 and preferably a non-reactive organic liquid which boils at a temperature not lower than 200 C., and preferably not lower than 250 C., at atmospheric pressure.

As illustrative examples of non-reactive organic liquids and solids which may be used in the practice of this inven- 7 tion, there may be mentioned trichlorobenzene, chlorinated biphenyl, chlorinated 1,3,3,-trimethyl 1 phenylindane, chlorinated 1,3,3,6 tetramethyl 1(4' methylphenyl)indane, dimethoxy tetraethylene glycol, diethyl phthalate, dibutyl phthalate, diamyl phthalate, butyl benzoyl benzoate, butyl phthalyl butyl glycolate, N-ethylpara-toluene sulfonamide, diphenyl ortho-biphenyl phosphate, tricresyl phosphate, 2-ethylhexyl diphenyl phosphate, dibutyl sebacate, dibenzyl sebacate, partially hydrogenated aromatic hydrocarbon liquid mixtures such as disclosed and claimed in Patent 2,364,719, epoxidized safiiower oil and petroleum and coal tar oils which boil above 200 C., and preferably above 250 C., at atmospheric pressure. In fact, any organic liquid or solid boiling within the above range which is compatible with the above adducts, the organic compounds containing urethane groups and the final resin may be employed in the practice of the instant invention.

' The above-described adducts may be preformed and then added to the non-reactive organic liquid or solid and converted to a more highly polymerized state or they may be formed in situ in the organic liquid or solid and then converted to a higher state of polymerization. In either event, the plasticized polymers thus obtained vary from soft resinous gels to hard brittle resins, depending upon the amount and type of components used in their production.

For a more complete understanding of the instant invention, reference is made to the following illustrative examples, although it should be clearly understoodthat the invention is not limited thereto.

Example I.Manufacture of Substantially Bubble-Free Gels and Resins About 11.1 parts of triethanolamine was reacted with about 38.9 parts of m-tolylene diisocyanate in the presence of about 50 parts of chlorinated biphenyl containing 42 percent chlorine. The resulting mixture consisted of a white solid suspended in a yellow liquid. This liquid was separated and heated in an oven at a temperature of C. for about 12 hours and a hard, clear resin was obtained.

A sample of this resin was held in a Bunsen flame and it burned with a smoky flame without melting but extinguished itself as soon as it was removed.

Example II About 55.5 parts or" triethanolamine and about 250 parts of chlorinated biphenyl containing 42 percent chlorine were mixed thoroughly in a flask and then about 194.5 parts of m-tolylene diisocyanate was added with stirring. During this addition, the reaction temperature was maintained at value not exceeding 50 C. This resulted in the production of a slurry of a solid material which was separated from the liquid by filtering. A sample of the liquid reaction product was placed in an oven at 100 C. and, after about 18 hours, the liquid solidified. The solubility of this product in various liquids was determined and it was found that the resin did not dissolve in boiling solvents such as water, methanol, acetone, hexane, benzene, carbon tetrachloride and ethyl acetate.

Example 111 A slurry containing about 39.1 parts of diethanolamine and about 250 parts of chlorinated biphenyl containing 42 percent chlorine was reacted with about 194.5 parts of m-tolylene diisocyanate to form a liquid product containing a relatively small proportion of solid material which was separated by filtering. The liquid product was then heated in an oven at 100 C. until it solidified into a hard, clear resin.

Example IV About 38.9 parts of m-tolylene diisocyanate and about 11.1 parts of triethanolamine were reacted together in the presence of about 50 parts of nuclear chlorinated isopropylbiphenyl containing about 42 percent chlorine. The reaction product consisted of a liquid containing a relatively small proportion of solids which were removed by filtration. The liquid portion of the reaction product was heated in an oven at 100 C. for a period of about 24 hours and a soft, yellow resinous gel was obtained.

Example V About 11.1 parts of triethanolarnine and about 38.9 parts of m-tolylene diisocyanate were reacted together in the presence of about 50 parts of the following solvents:

Sample No. 1Chlorinated biphenyl containing 21 percent chlorine Sample No. 2Chlorinated biphenyl containing 32 percent chlorine Sample No. 3Chlorinated biphenyl containing 42 percent chlorine Sample No. 4Chlorinated biphenyl containing 48 percent chlorine Sample No. 5-Chlorinated biphenyl containing 54 percent chlorine Sample No. 6Chlorinated biphenyl containing 60 percent chlorine Sample No. 7-Chlorinated naphthalene On heating to a temperature of 100 C. and for a period of about 20 hours, Samples Nos. 15 and 7 formed clear, amber resins whereas Sample No. 6 produced a sticky, opaque resin.

Example V1 About 55.5 parts of triethanolamine and about 194.5 parts of m-tolylene diisocyanate were reacted together in the presence of about 250 parts of chlorinated biphenyl containing 42 percent chlorine. This reaction was carried out at room temperature using chlorinated biphenyl which had been previously saturated with hydrogen chloride gas. This resulted in the production of a liquid containing a relatively small proportion of solids which were removed by filtration. A sample of this liquid product was heated at a temperature of 100 C. for about 3% hours to form a thick gel and for a total of about 4% hours to form a very hard and brittle resin which was substantially free of bubbles.

Example VII About 8.3 parts of triethanolamine and about 41.7 parts of p,p-diisocyanatodiphenylmethane were reacted together in the presence of about 50 parts of chlorinated biphenyl containing about 42 percent chlorine. The resulting reaction product was placed in a 100 C. oven and heated for about 5 hours. This resulted in the production of a hard, clear, yellow resin similar to that obtained with rn-tolylene diisocyanate.

Example VIII About 11.1 parts of triethanolamine was dissolved in about 50 parts of molten biphenyl and to the resulting solution about 38.9 parts of m-tolylene diisocyanate was added. The product obtained as a result of the ensuing reaction was heated for about 24 hours at 100 C. and a hard, clear, light yellow resin was obtained.

6 Example IX About 10.3 parts of castor oil was reacted with about 4.7 parts of m-tolylene diisccyanate in the presence of chlorinated biphenyl containing 42 percent chlorine, the reaction taking place at room temperature. The product of this reaction was a clear, viscous liquid which, on heating for about 40 hours at C., yielded a flexible, bubble-free resin.

Example X m-Tolylene diisocyanate and the condensate of about 6.6 mols of propylene oxide with 1 mol of glycerine were reacted together in a molar ratio of about 3 mols of the diisocyanate to about 1 mol of the condensate, the reaction taking place in the presence of a sufficient amount of chlorinated biphenyl containing 42 percent chlorine to yield a 50 percent solution of adduct. On heating for 2% hours at C., a sample of this solution yielded a tough, rubbery and resinous gel.

Example XI m-Tolylene diisocyanate containing about .23 percent of hydrolyzable chlorine was reacted with the following alkylene oxide condensates of glycerine in a molar ratio of about 3 mols of the isocyanate to about 1 mol of the condensate, the reaction taking place in the presence of suflicient amount of chlorinated biphenyl containing 42 percent chlorine to yield a 50 percent solution of the adduct.

Condensate of about 3.1 mols of propylene oxide with 1 mol of glycerine Condensate of about 13.2 mols of propylene oxide with 1 mol of glycerine Condensate of about 12 mols of ethylene oxide with 1 mol of glycerine Condensate of about 3 mols of ethylene oxide with 1 mol of glycerine Solutions of the following compositions, when heated for about 23 hours at 125 0, yielded substantially bubblefree products which varied with decreasing amounts of solvent from a soft jelly to a tough, flexible resin.

Percent by weight of chlorinated biphenyl containing 42% chlorine Adduct Percent by weight of adduct Adduct of about 3 mols of rn-tolylene diisocyanate with about 1 mol of the condensate of 13.2 mols of propylene oxide with 1 m 20 Example XIII Solutions of the following compositions, when heated for about 23 hours at 125 C., produced substantially 7 bubble-free, brittle resins which increased in hardness as the amount of solvent was decreased.

Percent by Weight of chlorinated Adduct Percent by biphenyl weight of containing adduct 42% chlorine Adduct of 3 mols of m-tolylene diisocyanate with 1 mol of the condensate of 3.1 mols of propylene oxide with 1 mol of glycerine 2O 80 Do 35 65 Do 65 35 D 80 20 Example XIV Physical appearance of adduct 1. Unrefined chlorinated biphenyl containing 48% by weight of chlorine .Chlorinated biphenyl containing 21% chlorine 3. Chlorinated biphenyl con- Dark liquid.

Clear, viscous liquid.

taining 32% chlorine Do. 4. Refined chlorinated biphenyl containing 48% chlorine Do. 5. Refined chlorinated biphenyl containing 54% chlorine Do.

Refined chlorinated biphenyl containing 60% chlorine Very viscous, clear liquid. Chlorinated mixture of 60% biphenyl and 40% distilled high boiler containing 65% chlorine Clear, extremely viscous liquid.

8. Chlorinated isomeric terphenyl mixture containing 42% chlorine Clear, extremely viscous liquid. 9. Chlorinated distilled high boiler containing 60% chlorine Clear solid.

The products obtained as a result of these reactions were heated at a temperature of 125 C. untila gel was formed, whereupon the heating was continued for a total of 13 hours to convert the gel into a resin. The time re quired to gel the above products and the type of resins formed are indicated in the following table.

Total time required Type of resin formed for sample to gel Dark, ilexible, soft, bubble-free Greater than 6 hours resin. 4 W

Flexligole, bubble-free resin.

2% hours 13 hours do Greater than 6 hours Do. Soft, flexible, bubble-free resin. S0155, flexible resin with a few bubes. 1% hours Hard, flexible, bubbletree resin.

Flexible, bubble-free resin.

Brittle resin with a few bubbles.

8 Example XV Substantially 3 mols of m-tolylene diisocyanate was reacted with about 1' mol' of the condensation product of about 13.2 mols of propylene oxide with 1 mol of glycerine, the reaction taking place in the presence of a sufiicient amount of the. following organic liquids to form a. 50 percent solution of the adduct. having the properties indicated:

Sample Organic liquid Physical properties of No. solution of adduct 1 Partially hydrogenated aromatic Clear, visc0us liquid.

liquid. mixture having a specific gravity of about 1.004 at 25 0., a refractive index of about 1.5600 at 25 C. and a boiling range of 340 C. to 390 C. at atmospheric pressure. 2 Chlorinated 1:3 :3-trin1ethyl-1- Do.

phenyl-indane. Epoxidized safflower oil Do. 4 Tricresyl phosphate Do. Zethylhexyl diphenyl phosphate Do. Butyl phthalyl butyl glycolate' Do. 7 Dimethoxy tetraethylene glycol..- Clear liquid.

The above products were heated at a temperature of about 125 C. until they were gelled and then the gels were heated up to a total of 22 /2 hours to convert them into resins. The time required for the products to gel and the properties of the resins are given in the following table. 7

Timerequired for sample Type of resin formed to gel, rs.

Flexible resin with some tendency of organic liquid to exude. Flex]'1)ble resin. 0.

Greater than 6% More than 2% Example XVI About 3 mols of m-tolylene diisocyanate was reacted with about 1 mol of the condensate of 13.2 mols of propylene oxide with 1 mol of glycerine, the reaction being executed in the presence of a sufficient amount of tricresyl phosphate or chlorinated biphenyl containing 42 percent chlorine to yield 20 percent, 50 percent and percent solutions of the adduct. A similar reaction was carried out using about 3 mols of m-tolylene diisocyanate and about 1 mol of the condensate of 3.1 mols of propylene oxide with 1 mol of glycerine. The resulting reaction products were further heated to yield resinous polymers plasticized by the solvent employed.

Similar products were also made by adding the above condensates to the following molten chlorinated compounds, reacting m-tolylene diisocyanate with the condensate in the molar ratioindicated above and then heating the resulting products to convert them into plasticized resinous polymers.

(1) A chlorinated mixture consisting of 60 percent bi phenyl and 40 percent distilled high boiler containing about 65 percent chlorine (2) A chlorinated isomeric terphenyl mixture containing 42 percent chlorine (3) Chlorinated distilled high boiler containing about 60 percent chlorine Example XVII About 8 parts of the condensate of 13.2 mols of propylene oxide with 1 mol of glyccrine was reacted with about 7 parts of p,p-diisocyanatodiphenylmethane which had been pretreated with HCl gas, the reaction being executed in the presence of 15 parts of chlorinated biphenyl containing about 42 percent chlorine. The product of this reaction was a soft, sticky, gummy, cloudy liquid. A sample of this product was heated at 125 C. for a period of about 15 hours and a clear, flexible resin substantially free of bubbles was obtained.

Example XVIII A mixture of about 15 parts of chlorinated biphenyl containing 42 percent chlorine and about 15 parts of the adduct of about 3 mols of m-tolylene diisocyanate with about 1 mol of the condensate of 9.2 mols of ethylene oxide with 1 mol of triethanolamine was prepared and then heated at 140 C. for about 25 to 30 minutes. This yielded a clear, tough, resinous product.

Example XIX About 40.7 parts of the condensate of 11.98 mols of ethylene oxide with 1 mol of glycerine was reacted with about 34.3 parts of m-tolylene diisocyanate containing 0.24 percent hydrolyzable chlorine, the reaction being executed in the presence of about 75 parts of chlorinated biphenyl containing 54 percent chlorine. The product of this reaction was heated at 110 C. for about 115 hours and a clear resin was obtained. A sample of this resin was held in the flame until it was burning well and then it was withdrawn. On being withdrawn, the product did not continue to burn.

Example XX About 244 parts of the condensate of 11.98 mols of ethylene oxide with 1 mol of glycerine was reacted with about 205.3 parts of m-tolylene diisocyanate containing 0.24 percent of hydrolyzable chlorine, the reaction taking place at room temperature and in the presence of about 450 parts of chlorinated biphenyl containing 42 percent chlorine. This reaction yielded a product which, on heating at about 110 C. for a period of about 68 hours, produced a completely bubble-free, clear, flexible and tough resln.

A sample of the product of the initial reaction was used to impregnate and/or laminate glass cloth with highly satisfactory results. In producing these products, the solution of the initial reaction product was applied to a sheet of cloth and also between two sheets of cloth and then heated to effect polymerization of the adduct.

Example XXI About 6.8 parts of the condensate of 11.98 mols of ethylene oxide with 1 mol of glycerine was reacted with about 8.2 parts of p,p'-diisocyanatodiphenylmethane in the presence of about 15 parts of chlorinated biphenyl containing 42 percent chlorine, the reaction taking place at room temperature. The isocyanate used in this reaction was pretreated with hydrogen chloride to insure the presence of a trace of HCl. The product of this reaction was a very viscous, sticky liquid which, on heating at a temperature of about 125 C. for about 15 hours, yielded a flexible, clear resin substantially free of bubbles.

Example XXII.Manufacture of Resinous Foams verted initially into a gel and finally into a porous resinous foam.

' Example XXIII The procedure used in Example XI was repeated using m-tolylene diisocyanate which had been pretreated with hydrogen chloride, and a condensate of about 3 mols of propene oxide with 1 mol of glycerine to form a 50 percent solution of adduct. A sample of this solution was mixed with about 1 percent by weight of lead oxide and the resulting mixture heated at 140 C. for about 1% to 1% hours. This resulted in the production of a rubbery, resinous foam.

Example XXIV About 66.2 parts of castor oil was dissolved in about parts of chlorinated biphenyl containing 54 percent chlorine by heating and to the resulting solution about 33.8 parts of m-tolylene diisocyanate and about 5 parts of N-methylmorpholine were successively added. After the formation of the adduct had been completed, about 1 percent of N-methylmorpholine and about 0.4 percent of benzyltrimethylammonium hydroxide were introduced with stirring. The ensuing reaction, which was carried out at room temperature, resulted in the production of a resinous foam. This product was given an additional cure by heating for 15 minutes at about 100 C. and a light colored rubbery foam or" substantially uniform cell size was obtained.

Example XXV The preceding example was repeated using hydrogenated instead of natural castor oil. This resulted in the production of a light colored rubbery foam which was slightly firmer than that obtained in the previous example.

The organic compound containing a urethane or thiourethane group or one or more of these groups and an isocyanate and/or an isothiocyanate group is desirably prepared in the presence of a non-reactive organic plasticizer, preferably a non-reactive organic liquid plasticizer, which boils at a temperature of at least 200 C. and preferably at a temperature of at least 250 C. at atmospheric pressure. This yields a solid or a viscous liquid solution of the above organic compound, which is stable for a considerable period of time if stored at room temperature in tightly closed containers. However, if heated or treated in the manner hereinafter described, the solution is converted into a complex resinous polymer plasticized by the above-mentioned plasticizer.

The curing of the solid or viscous liquid solution of the above-mentioned organic compound is effected by heating in the substantial absence of moisture or other foreign materials containing reactive hydrogen atoms. This heating is sufilcient to effect a reaction between at least one urethane or thiourethane group and an isocyanate and/ or an isothiocyanate group of another molecule containing both types of functional groups. In the event that the organic compound contains only urethane or thiourethane groups, then it is cured by reaction with an added compound which contains at least one isocyanate and/ or isothiocyanate group, the curing taking place at a temperature sufficient to bring about a reaction between the functional groups of the two compounds involved.

The curing operation is carried out in the absence or presence of a catalyst and at a temperature varying from room temperature up to about 225 C. or more specifically, from about 60 C. to about 200 C. and within these limits, a temperature of about 100 C. to about C. is preferred.

In the production of cellular products or plastic foam, the curing is effected at room temperature by merely mixing the organic material containing a urethane or a thiourethane group or a solution thereof with a relatively small proportion of a catalyst selected from the group consisting of compounds yielding in aqueous solution ionizable hydroxyl or substituted hydroxyl groups and precursors of these compounds. The expression substituted hydroxyl groups signifies radicals of the formula -OX, in which X is a member selected from the group consisting of aliphatic, cycloaliphatic, aryl, alkaryl, aralkyl and substituted hydrocarbon radicals which may or may not be interrupted by non-reactive hetero atoms such 1 1 as sulfur and oxygen, etc. carbon radicals may be substituted by alkyl, alkoxy, halogen and/or nitro groups. Illustrative examples of preferred catalysts with'the group are the oxides or hydroxides of potassium, sodium and calcium; the oxides of magnesium, Zinc and lead; the alkali metal saltsand particularly the sodium salts of ortho-phenyl phenol, 2,4,5,- trichlorophenol and 2,3,4,6-tetrachlorophenol; and benzyltrimethylammonium hydroxide, tetramethylammonium hydroxide, tetramethylphenylammonium hydroxide, tetraethylammonium hydroxide, etc. These catalysts may be used alone or in combination with tertiary organic amines suchas N-methylmorpholine, N-ethylmorpholine, tri'ethylarnine, tripropylamine, tributylamine, triamylamine, pyridine and quinoline, etc. If desired, the rate of curing may be greatly accelerated by heating the solid or liquid solution to higher temperatures within the limits set forth above. The curing may be carried out in the absence or presence of moisture or a plasticizer.

In the production of cellular products or plastic foams, the catalyst is employed in an amount varying from about 0.001 percent to about 5 percent by Weight or more specifically within the range of about 0.1 percent to about 3 percent by weight and within these limits about 0.5 percent to about 1 percent is preferred. The percentage by weight is based upon the weight of the total reactants.

In the production of plasticized products in accordance with this invention, the liquid or solid plasticizer is desirably employed in an amount varying from about percent to about 80 percent by weight, basis total weight,

and within these limits about 40 percent to about 60 percent by weight is preferred. If desired, larger or smaller amounts may be employed in order to effect the desired degree of plasticization.

The plasticized products of the instant invention cannot be produced by first forming the polymerized or cured organic compound containing a urethane or thiourethane group and then incorporating the cured product with the plasticizer. In order to obtain products having satisfactory properties, the organic compound containing the urethane or thiourethane group must be intimately associated with the plasticizer and then polymerized or cured to a higher molecular state. In this operation, the organic compound containing the urethane or thiourethane group may be preformed and then added to the plasticizer or it may be formed in situ.

What is claimed is:

1. In the preparation of a, substantially non-porous polyurethane plastic by a process which comprises reacting an organic compound containing at least two active hydrogen containing groups in the molecule, said active hydrogen containing groups being reactive with isocyanate groups, with a member selected from the class consisting of an organic polyisocyanate and an organic polyisothiocyanate present in the reaction mixture in a ratio of more than one mol thereof per mol of said active hydrogen bearing compound to form a liquid adduct having terminal groups selected from the class consisting of'NCO and NCS groups and thereafter effecting solidification through chain lengthening, the'improvement which comprises eflFecting the said chain lengthening until a solid substantially non-porous product is obtained while the adduct is associated with an inert organic plasticizer of a polyurethane plastic having a boiling point of at least about 200 C. at atmospheric pressure in the absence of any substantial amount of any added compound containing active hydrogens whereby said chain lengthening is achieved primarily through reaction of groups selected from. the class consisting of NCO and NCS groups with reactive hydrogens on said adduct and through reaction of terminal groups of the last said class with each other. 2'. As anew composition of matter, the product obtained by reacting a compound selected from the class consisting of an organic polyisocyanate and an organic For example, these hydro- 1.2 polyisothiocyanate with an organic compound having hydrogen atoms reactive with an NCO group, the ratio of said class member to organic compound having reactive hydrogens being greater than 1:1, and thereafter heating the resulting adduct having terminal groups'selected from the group consisting of NCO and NCS groups under substantially anhydrous conditions and at a temperature of at least about 60 C. until chain lengthening through reaction of said terminal groups of the adduct with each other with the formation of a substantially non-porous product of greater molecular weight.

3. As a new composition of matter, the product obtained by reacting a compound selected from the class consisting of an organic polyisocyanate and polyisothiocyanate with an organic compound having hydrogen atoms reactive with an NCO group, the ratio of said class member to organic compound having reactive hydrogens being greater than 1:1, and thereafter heating the resulting adduct having terminal groups selectedfrom the group consisting of NCO and NCS groups under substantially anhydrous conditions and at a temperature of from about C. to about C. until chain lengthening through reaction of said terminal groups ofthe adduct with each other With the formation of a substantially non-porous product of greater molecular weight.

4. As a new composition of matter, the product obtained by reacting a compound selected from the class consisting of an organic polyisocyanate and polyisothiocyanate with an organic compound having hydrogen atoms reactive with an NCO group, the ratio of said class member to organic compound having reactive hydrogens being greater than 1:1, whereby the resulting adduct has terminal NCO groups, and polymerizing the said adduct by reaction of NCO groups with each other while mixed with an inert compatible organic plasticizer having a boiling point of at least about 200 C.

5. The product prepared by reacting castor oil with a compound selected from the group consisting of an organic polyisocyanate and polyisothiocyanate to form an adduct having terminal groups selected from the group consisting of NCO and NCS groups and thereafter heating the adduct under substantially anhydrous conditions to a temperature of at least about 60 C. to effect reaction of the said terminal groups with each other.

6. A cured polyurethane prepared by a process comprising reacting a compound selected from the group consisting of an organic polyisocyanate and polyisothiocyanate with an organic compound having hydrogens reactive with an NCO group, the ratio of said reactants in the resulting mixture. being more than 1 mol of the class member per mol of compound having reactive hydrogens, and curing the resulting product having terminal groups selected from the group consisting of NCO and NCS groups by heating it to at least 60 C. while in admixture with a compound selected from the group consisting of an organic polyisocyanate and polyisothiocyanate through reaction of the said terminal groups with each other to form a substantially non-porous polyurethane.

V 7. A method for making polymers which comprises reacting a compound having the formula R(NCX) with an organic compound having hydrogen atoms reactive with said NCX groups in a ratio of R(NCX) to organic compound having reactive hydrogen atoms of more than 1:1, respectively, and thereafter heating the resulting adduct having terminal NCX groups to at least 60 C. under substantially anhydrous conditions until reaction of the said terminal groups with each other with the formation of a substantially non-porous product of greater molecular weight; R in the foregoing formula being an organic radical free from functional groups other than NCX, urethane and thiourethane groups, X being se- 13 lected from the group consisting of oxygen and sulfur and n being an integer of at least 2.

8. A method for making a polyurethane which comprises reacting a compound having the formula R(NCX) with an organic compound having hydrogen atoms reactive with an NCX group, the ratio of the reactants in the reaction mixture being more than 1 mol of RfNCX), per mol of the other said reactant, and curing the resulting product having terminal NCX groups by heating it to at least 60 C. While in admixture with a compound having the formula R(NCX) by reaction of the terminal groups with each other to form a substantially non-porous product; R in said formula being an organic radical, X being selected from the group consisting of oxygen and sulfur and n being an integer of at least 2.

9. A method for making polymers which comprises reacting a compound having the formula R(NCX) with an organic compound having hydrogen atoms reactive with saidNCX groups in a ratio of R(NCX) to organic compound having reactive hydrogen atoms of more than 1:1, respectively, and thereafter heating the resulting adduct having terminal NCX groups under substantially anhydrous conditions and at a temperature of from about 100 C. to about 125 C. until the reaction of the said terminal groups with each other with the formation of a substantially non-porous product of greater molecular weight; R in the foregoing formulabeing an organic radical free from functional groups other than --NCX, urethane and thiourethane groups, X being selected from the group consisting of oxygen and sulfur and n being an integer of at least 2.

10. A method for making polymers which comprises reacting a compound having the formula R(NCX) with an organic compound having hydrogen atoms reactive with said NCX groups in a ratio of R(NCX) to organic compound having reactive hydrogen atoms of more than 1:1, respectively, and an inert compatible organic liquid having a boiling point of at least about 200 C. and maintaining the resulting mixture under substantially anhydrous conditions until reaction of NCX groups with each other with the formation of a substantially nonporous product of greater molecular Weight; R in the foregoing formula being an organic radical free from functional groups other than NCX, urethane and thiourethane groups, X being selected from the group consisting of oxygen and sulfur and n being an integer of at least 2.

11. A method for making polymers which comprises reacting a compound having the formula R(NCX) with an organic compound having hydrogen atoms reactive with said NCX groups in a ratio of R(NCX) to organic compound having reactive hydrogen atoms of more than 1:1, respectively, and thereafter heating at a temperature of at least about C. a mixture of the resulting adduct and an inert, compatible organic liquid having a boiling point of at least about 200 C. until polymerization reaction of NCX groups with each other with the formation of a substantially non-porous product of greater molecular weight; R in the foregoing formula being an organic radical free from functional groups other than NCX, urethane and thiourethane groups, X being selected from the group consisting of oxygen and sulfur and n being an integer of at least 2.

12. In the preparation of a polyurethane plastic by a process which comprises reacting an excess of a compound selected from the group consisting of an organic polyisocyanate and an organic polyisothiocyanate and an organic compound selected from the group consisting of a polyalkylene ether alcohol having from 2 to 4 hydroxyl groups and having a molecular weight of at least about 200 and castor oil, the improvement which comprises effecting the said reaction in the presence of a catalytic amount of N-alkyl morpholine.

13. The process of claim 12 wherein said N-alkyl morpholine is N-methyl morpholine.

14. The process of claim 12 wherein said N-alkyl morpholine is N-ethyl morpholine.

References Cited in the file of this patent UNITED STATES PATENTS 2,349,756 Pratt May 23, 1944 2,511,544 Rinke et al. June 13, 1950 2,577,281 Simon Dec. 4, 1951 2,602,783 Simon et al. July 8, 1952 2,621,166 Schmidt et al Dec. 9, 1952 2,625,531 Seeger Ian. 13, 1953 2,650,212 Windemuth Aug. 25, 1953 2,729,618 Muller et al. Jan. 3, 1956 2,741,800 Brockway April 17, 1956 2,772,245 Simon et al. Nov. 27, 1956 2,787,601 Detrick et al. Apr. 2, 1957 2,811,493 Simon et a1 Oct. 29, 1957 3,055,871 Heffler et a1 Sept. 25, 1962 

1. IN THE PREPARATION OF A SUBSTANTIALLY NON-POROUS POLYURETHANE PLASTIC BY A PROCESS WHICH COMPRISES REACTING AN ORGANIC COMPOUND CONTAING AT LEAST TWO ACTIVE HYDROGEN CONTAINING GROUPS IN THE MOLECULE, SAID ACTIVE HYDROGEN CONTAINING GROUPS BEING REACTIVE WITH ISOCYANATE OF AN ORGANIC POLYISOCYANATE AND AN ORGANIC POLYISOTHIOCYANATE PRESENT IN THE REACTION MIXTURE IN A RATIO OF MORE THAN ONE MOLE THEREOF PER MOLE OF SAID ACTIVE HYDROGEN BEARING COMPOUND TO FORM A LIQUID ADDUCT HAVING TERMINAL GROUPS SELECTED FROM THE CLASS CONSISTING OF -NCO AND -NCS GROUPS AND THEREAFTER EFFECTING SOLIDIFICATION THROUGH CHAIN LENGTHENING, THE IMPROVEMENT WHICH COMPRISES EFFECTING THE SAID CHAING LENGTHENING UNTIL A SOLID SUBSTANTIALLY NON-POROUS PRODUCT IS OBTAINED WHILE THE ADDUCT IS ASSOCIATED WITH AN INERT ORGANIC PLASTICIZER OF A POLYURETHANE PLASTIC HAVING A BOILING POINT OF AT LEAST ABOUT 200*C. AT ATMOSPHERIC PRESSURE IN THE ABSENCE OF ANY SUBSTANTIAL AMOUNT OF ANY ADDED COMPOUND CONTAINING ACTIVE HYDROGENS WHEREBY SAID CHAIN LENGTHENING IS ACHIEVED PRIMARILY THROUGH REACTION OF GROUPS SELECTED FROM THE CLASS CONSISTING OF -NCO AND -NCS GROUPS WITH REACTIVE HYDROGENS OF SAID ADDUCT AND THROUGH REACTION OF TERMINAL GROUPS OF THE LAST SAID CLASS WITH EACH OTHER. 